Repulpable container

ABSTRACT

A repulpable insulated container assembly having a container formed of paper such as corrugated cardboard or varying paper materials and defining an interior; and a repulpable insert placed within the interior of the container and formed of a first paper layer; and a paper fiber pad coupled to the first paper layer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 17/123,673, filed Dec. 16, 2020, which is acontinuation application of U.S. patent application Ser. No. 16/414,309,filed May 16, 2019 (issued as U.S. Pat. No. 10,882,682 on Jan. 5, 2021),which is a divisional application of U.S. patent application Ser. No.15/677,738, filed Aug. 15, 2017 (issued as U.S. Pat. No. 10,583,977 onMar. 10, 2020), which claims the benefit of U.S. Provisional ApplicationNo. 62/375,555, filed on Aug. 16, 2016, U.S. Provisional Application No.62/419,894, filed on Nov. 9, 2016, and U.S. Provisional Application No.62/437,365, filed on Dec. 21, 2016. The entire disclosure of the aboveapplications are incorporated herein by reference.

JOINT RESEARCH AGREEMENT

The subject matter disclosed was developed and the claimed invention wasmade by, or on behalf of, one or more parties to a joint researchagreement between MP Global Products LLC of Norfolk, Nebr. and PrattRetail Specialties, LLC of Conyers, Ga., that was in effect on or beforethe effective filing date of the claimed invention, and the claimedinvention was made as a result of activities undertaken within the scopeof the joint research agreement.

FIELD

The present invention relates to a method and system for producinginsulation materials and containers using the insulation materials aswell as the insulation material and containers using the insulationmaterial and more particularly to a method and system for producingrepulpable insulation materials, and recyclable containers usingrepulpable insulation material.

BACKGROUND

Insulated boxes are widely used in many shipping applications. Aninsulated box is desirable when shipping materials need to be shipped atreduced or elevated temperatures and to help with impact. Similarly,insulated boxes are desirable when shipping materials need to avoidlarge temperature swings. Such boxes may also lessen impact stresses onthe product and thereby lengthen the life of the product being shippedand/or make the product appear to be more durable and of a higherquality. Unfortunately, insulated materials are typically made ofdisparate materials from those used to form boxes thereby makingrecycling impossible.

SUMMARY

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features.

According to the present teachings, disclosed is an insulated containerand associated methods, systems, and apparatus. The insulated containercan include material allowing for the insulated container to berepulpable. The insulated container can comprise material formed of amethod, the method including mixing paper fibers with arecycling-compatible fiber to form a mixture of material. The mixturecan be disposed onto a surface to form a layer of the mixture. At leastone of heat and heat and pressure can be applied to the layer of themixture to form a paper fiber batt. The paper fiber batt can be trimmedso it has a fixed width and fixed length. The paper fiber batt can bepositioned adjacent to a corrugated box, with the shipping containerhaving a repulpability of greater than 85%.

According to an alternate teaching, the methods described above orbelow, include mixing paper fibers with a meltable polyethylene andpolypropylene (“PE/PP”) bi-component thermoplastic fiber.

According to the present teachings, disclosed is a method for producingan insulation material. The method includes mixing paper reinforcementfibers with between about 0.5% to about 25% by weight meltable PE/PPbi-component thermoplastic binder fiber having a length less than about16 mm. The PE/PP bi-component thermoplastic binder fibers aredistributed substantially randomly within the paper reinforcement fibersto form a mixture. Heat is applied to the mixture to melt the PE/PPbi-component thermoplastic binder fiber to bind the PE/PP bi-componentthermoplastic binder fiber to the paper reinforcement fibers to form abatt. The insulation material has the physical property of beingrepulpable at a rate greater than 85%.

According to an alternate teaching, in the methods described above orbelow, the methods include coupling a repulpable paper layer to the battto form an insulative batt assembly.

According to an alternate teaching, in the methods described above orbelow, the methods include forming a repulpable paper fiber pad having acompression resistance of between about 0.3 psi and about 1.4 psi atcompressions of between about 25% and about 50%.

According to an alternate teaching, in the methods described above orbelow, the methods include forming a repulpable paper fiber pad having acompression set at about 25% of between about 5% and about 18%.

According to an alternate teaching, in the methods described above orbelow, the methods include forming disposing a water soluble adhesivelayer between the paper fiber pad and the first paper layer.

According to the present teachings, disclosed is method for producing aninsulation material. A mixture of paper fiber with between 0.5% and 25%thermoplastic binder fiber distributed substantially randomly within thepaper fiber is formed. The mixture is heated to bring the thermoplasticbinder fiber above a fiber's glass transition temperature or meltingpoint, thus binding the thermoplastic binder fiber to the paper fiber toform a batt having a density of less than 5 pound per cubic foot. Thefibrous web of paper fibers are interlocked with the thermoplasticbinder fiber while the batt is subsequently brought to a temperaturebelow the glass transition temperature of the thermoplastic fiber toform an insulative pad that is greater than 85% repulpable. This pad isdisposed within one of an interior surface of a repulpable corrugatedcardboard box or a repulpable envelope, to form an assembly that isgreater than 85% repulpable.

According to an alternate teaching, in the methods described above orbelow, forming a mixture of paper fiber and thermoplastic binder isforming a mixture of paper fiber with between about 0.5% and about 25%PE/PP bi-component thermoplastic fiber having a length of less thanabout 24 mm.

According to an alternate teaching, in the methods described above orbelow, forming a mixture of paper fiber with thermoplastic binder fiberis forming an mixture of paper fiber with between about 5% and about 10%PE/PP bi-component thermoplastic binder fiber having varying lengths andhaving an average length of less than about 16 mm.

According to the present teachings, containers, shipping containers,insulative materials, and insulative constructions described above orbelow or produced using the methods described above and below, aregreater than 85% repulpable and have a repulpable paper layer and arepulpable paper fiber pad coupled to the paper layer. The paper fiberpad has paper reinforcement fibers interlocked with about 2% to about25% by weight meltable PE/PP bi-component thermoplastic binder fiberdistributed substantially randomly therein.

According to the present teachings in the containers, shippingcontainers, insulative materials, and insulative constructions describedabove or below or produced using the methods described above and below,the meltable thermoplastic fiber is a chopped fiber having lengthsbetween about 0.5 mm to about 16 mm.

According to the present teachings, in the containers, shippingcontainers, insulative materials, and insulative constructions describedabove or below or produced using the methods described above and below,the meltable thermoplastic fiber can be a chopped fiber PE/PPbi-component having lengths between about 0.5 mm to about 16 mm.

According to the present teachings, the containers, shipping containers,insulative materials, and insulative constructions described above orbelow or produced using the methods described above and below, furtherhave a repulpable corrugated cardboard disposed adjacent to the paperlayer.

According to the present teachings, the containers, shipping containers,insulative materials, and insulative constructions described above orbelow or produced using the methods described above and below, furtherhave a recycling-compatible or water soluble adhesive layer disposedbetween the paper layer and the corrugated cardboard.

According to an alternate teaching, in the methods described above orbelow, the methods include placing lose ground-up fibrous cellulouspaper or ground-up cardboard material onto a moving conveyor. The fibersin the fibrous paper or cellulous material can be interlocked by methodssuch a needling or by use of a melted binder fiber, a bioresorbableadhesive, recycling-compatible, water soluble adhesive, plant based(sugar or pectin) adhesive from, for example, sugar beet, corn, or sugarcane, or starch. The ground up cellulous paper or cardboard material isformed into a slab or batt by passing the continuous layer of materialbetween a pair of tapered edge plates which forms the batt width andthickness of the uncompressed batt. This material can have its thicknessand density adjusted using a compression roller which can apply heat.

According to an alternate teaching, in the methods described above orbelow, the methods include, after compression, the batt being cut intoindividual pieces using a slicing knife. Optionally, the batt can be cutin half along its thickness using a moving slicing knife or blade. Oncethe batt is formed into a rectangular shape and thickness, the materialis then ready for coupling to or disposing in an inner corrugated box orenvelope.

According to an alternate teaching, in the methods described above orbelow, the methods include taking an inner corrugated box surface off ofa roll of appropriate material. The inner corrugated box surfacematerial is cut into specific lengths and widths. For example, thecardboard box inner surface material can have a width and length largerthan the width and length of the fibrous batt.

According to the present teachings, containers, shipping containers,insulative materials, and insulative constructions described above orbelow or produced using the methods described above and below, include apaper layer that can be disposed over the batt, overlapping the expandedportions of the batt underneath all four sides. The ends of the paperlayer can be wrapped about and tucked under the ends of the batt. Heator recycling-compatible or water soluble adhesive can be applied to fixthe inner paper layer to the batt.

According to an alternate teaching, in the methods described above orbelow, the methods include adhering an inner paper layer to the batt onan outside surface of the inner paper layer which can be folded to forma pocket. The folded batt is then placed through an end closureapparatus which closes the side of the inner paper layer, thus forming apocket. The edges of the folded batt can be sewn shut using anindustrial sewing machine.

According to an alternate teaching, in the methods described above orbelow, the methods include positioning another paper layer about theoutside of the folded batt. The outer paper layer can be positionedabout the batt on the inner paper layer in a manner which forms aclosable flap. This closable flap can include a recycling-compatible orwater soluble adhesive in the form of dual sided tape.

According to an alternate teaching, in the methods described above orbelow, the methods include encapsulating the insulative batt materialbetween the inner and outer paper layer. In this regard, the edge of theouter paper layer can be coupled to the inner paper layer using heat orrecycling-compatible or water soluble adhesive, or stitching. Excessmaterial along the edges can be removed.

According to the present teachings, insulative materials, and insulativeconstructions described above or below or produced using the methodsdescribed above and below, can include forming cellulous fibers bypassing recycled cardboard through a hammer mill. These fibers are mixedwith paper and with one of a recycling-compatible fiber. Therecycling-compatible fiber can be a meltable thermoplastic fiber. Aninsulative paper fiber batt having a first width and first length isformed from the recycled paper fibers. A first paper layer is coupled tothe paper fiber batt. The paper fiber batt is coupled to a corrugatedbox.

Further areas of applicability will become apparent from the descriptionprovided herein. The description and specific examples in this summaryare intended for purposes of illustration only and are not intended tolimit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected embodiments and not all possible implementations, and are notintended to limit the scope of the present disclosure.

FIG. 1 represents the formation of an insulative batt or pad for aninsulative mailer;

FIG. 2 represents positioning a recyclable paper layer over theinsulative pad shown in FIG. 1 ;

FIG. 3 represents the cutting of the recyclable paper layer positionedover the pad as shown in FIG. 2 ;

FIG. 4 represents positioning the paper layer about the edges of thepad;

FIG. 5 represents the application of heat to bind the paper layer to thepad;

FIG. 6 represents folding the construction of FIG. 5 into a pocket;

FIG. 7 represents sewing the sides of the construction of FIG. 6 to forma pocket;

FIG. 8 represents the application of an adhesive;

FIG. 9 represents the application of an outer paper layer about theconstruction of FIG. 8 ;

FIG. 10 represents heat sealing and cutting the inner and outer paperlayer of the constructions of FIG. 9 ;

FIG. 11 represents the mailer formed using the methods and systems ofFIGS. 1-10 ;

FIG. 12 represents a system to form a box liner according to anotherteaching of the present invention;

FIGS. 13 a-13 b represent the cutting of and formation of an insulativebatt or pad;

FIGS. 14 a-14 c represent the application of an upper paper layeraccording to the present teachings;

FIGS. 15 a-15 b represents the application of an optional bottom paperlayer;

FIGS. 16 a and 16 b represent side sealing of the paper layers about theinsulative member;

FIG. 17 represents a heat tunnel used to form the insulative memberaccording to the present teachings; and

FIGS. 18 a-18 b represent the insulative batt coupled to a corrugatedbox.

Corresponding reference numerals indicate corresponding parts throughoutthe several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference tothe accompanying drawings.

The formation of an insulated material and an insulated mailer or ashipping container will be described in the description of FIGS. 1-12 .As shown in FIG. 1 , fibrous paper or cellulous material 2 is placedonto a moving conveyor 4. The fibers can be interlocked by methods sucha needling or by use of a melted binder which represents about 2% toabout 25% of the fiber by weight which is mixed within the fibrous paperor cellulous material. Alternatively, the fibers can be bound usingrecycling-compatible or water soluble adhesive. The fibrous paper orcellulous material 2 is formed into a slab 10 by passing the continuouslayer of material 2 between a pair of tapered edge plates 11 (only oneshown) that form the batt width. The thickness of the uncompressed slab10 can be defined by an upper rake or block 14. This material can thenhave its thickness and density adjusted using a compression roller 16(FIG. 3 ).

After compression, the slab 10 is converted to a paper fiber insulativebatt 22 (FIG. 2 ), which can be manufactured fiber compositions formedby passing recycled cardboard through a mill such as a hammer mill. Thebatt 22 can contain small amounts of water soluble adhesive or meltablefibers such a polypropylene fiber. Optionally, randomly distributednatural fibers such as cotton and binder fibers having lengths betweenabout 1/16 inch to about 1.5 inches and a denier of between about 5 andabout 12 are used to form the paper fiber batt 22, which is processed toform the insulative pad 46 (FIG. 3 ).

Additionally, the binder fibers can be a water soluble PVOH fiber whichcan have a denier of about 0.02 to about 3.0, a water temperature atmore than about 100 degrees C., and a cut length of about 2 mm to about8 mm. The binder fiber can be, for example, a KURALON™ brand short cutfibers. As a binder fiber, the recyclable PVOH fiber used in theinsulation can be about a 0.4 denier to about a 1.0 denier fiber havinga length of about 3.0 to about 4.0 mm.

The insulative material 22 is continuously fed on the conveyor 4 betweena pair of side guides which define a pair of sides for a continuousstrip of insulative material. The side guides define a predeterminedwidth for the pad. Once aligned, the continuous strip of material ispositioned under a slicing mechanism which cuts the continuous batt 22into predefined lengths thus forming the insulative pad 46.

As seen in FIG. 2 , the batt 22 is transported via the conveyor 4 to asecond location where an inner paper layer 25 is draped over the pad 46.The inner paper layer 25 has a length and a width larger than the lengthand width of the pad 46. First and second ends 26 of the inner paperlayer 25 can be tucked under first and second ends 28 of the pad 46.

As shown in FIG. 3 , the batt 22 can then be cut into individual piecesusing a slicing knife 12 which can be a rotating band or circular blade.Optionally, the batt 22 can be cut in half along its thickness using theslicing knife 12. Once the batt 22 is formed into a rectangular shapeand thickness, the material is then ready for coupling to or placedadjacent an inner corrugated box inner surface.

The inner paper layer 25 is taken off of a roll of appropriate materialthat can for instance be pre-perforated or water proofed. As shown inFIGS. 3 and 4 , the paper box inner surface material is positioned overthe insulated layer and is cut into specific lengths and widths. Forexample, the paper box inner surface material can have a width andlength larger than the width and length of the fibrous pad 46.

As shown in FIG. 4 , the inner paper layer 25 is disposed over the pad46, overlapping the pad 46 on all four sides. The ends 26 of the innerpaper layer 25 are wrapped about and tucked under the ends 28 of the pad46. As shown in FIG. 5 , heat or recycling-compatible or water solubleadhesive can be applied to fix the inner paper layer 25 to the pad 46.The inner paper layer 25 is then folded in half, placing the pad 46 onan outside surface of the inner paper layer 25 which is disposed againstitself, thus forming a subassembly.

As shown in FIG. 6 , the folded pad 46 is then placed through an endclosure apparatus which closes the sides of the inner paper layer 25,thus forming a pocket 31. As shown in FIG. 7 , the edges can be sewnshut using an industrial sewing machine 80 or can be heat staked asappropriate. A row of smaller stitches 84 extend from top to bottom ofthe subassembly along each side thereof juxtaposed adjacent to thelateral edges 82 of pad 46. Spaced slightly inwardly of stitches 84 is asecond row of larger stitches 86 that encompass the pad 46 and the paperlayer 25 on the inside of the pad 46 and include portions 78 on theoutside of the pad 46. The second rows of stitches 86 only extendlongitudinally from the top of the subassembly downwardly and terminatewith the portions 78.

FIG. 8 represents the application of the recycling-compatible or watersoluble adhesive to assist binding an outer sheet or paper layer 32 tothe inner paper layer 25. Shown in FIG. 9 , the outer paper layer 32 canthen be positioned about the outside of the folded pad 46. The outerpaper layer 32 can be positioned about the pad 46 on the inner paperlayer 25 in a manner which forms a closable flap 56. This closable flap56 can take a recycling-compatible or water soluble adhesive 36 in theform of dual sided tape.

The outer paper layer 32 is then coupled to the inner paper layer 25,encapsulating the insulative material or pad 46 between the inner andouter paper layers 25 and 32 to form a shipping container or mailer 40(FIG. 11 ). In this regard, the edge of the outer paper layer 32 can becoupled to the inner paper layer 25 using heat, recycling-compatible orwater soluble adhesive, or stitching. Excess material along the edgescan be removed.

The outer paper layer 32 forming the outer surface of the mailer orshipping container 40 can be recyclable and can be finished so as to bewaterproof or water resistant. Optionally, the outer paper layer 32extends laterally so its lateral edges or margins 44 can be heat sealedtogether as shown in FIG. 10 . At the bottom of the mailer 40, the paperlayer 32 is folded at 52. At the top of the mailer 40 the front top edge58 terminates at the mailer opening 54, and the back continues upwardlyto form flap 56 to enable the mailer 40 to be sealed by folding the flap56 over the front top edge 58 of the mailer 40 closing off the opening54. The flap 56 has a lateral stripe of recyclable orrecycling-compatible or water soluble adhesive 30 covered with aremovable protecting paper 62.

As evident from the above description, the pad 46 is covered by theinner paper layer 25 on the inside with the inner paper layer 25extending laterally beyond the pad 46 to lie coextensive with themarginal edges 44 of the outer paper layer 32 so all marginal edges canbe heat sealed together. The inner paper layer 25 extends around thelongitudinal extremities of the pad 46 so that the end portions 82 ofthe inner paper layer 25 lie between the pad 46 and the outer paperlayer 32 when the pad 46 is located in the mailer 40. These portions 82enable the inner paper layer 25 to be heat sealed together with theouter paper layer 32 around the mailer opening 54, thereby entrappingthe pad 46. The portion of the opening 54 that lies with the flap 56 haspressure-sensitive, biodegradable tape 59 (covered with a protectivestrip 64) in order to seal the top edges of the inner paper layer 25together before the flap 56 is sealed to the front of the mailer 40.Apart from the stitching and heat sealing of the outer paper layer 32 tothe inner paper layer 25, the pad 46 is not attached to the outer paperlayer 32.

The fibers of the pad 46 can, for example, be about 75% recyclablecardboard and paper fiber and about 25% binder fiber having a weight ofabout 1600 grams per square (GSM) i.e., (75/25). Additional fibermaterial construction can be about 80/20 recyclable cardboard/paperfiber and binder fiber at about 1500 GSM; about 80/20 recyclablecardboard/paper fiber and binder fiber at about 1400 GSM; about 85/15recyclable cardboard/paper fiber and binder fiber at about 1600 GSM;about 85/15 recyclable cardboard/paper fiber and binder fiber at about1500 GSM; about 85/15 recyclable cardboard/paper fiber and binder fiberat about 1400 GSM; and about 90/10 recyclable cardboard/paper fiber andbinder fiber at about 1500 GSM, with the first number being the papercardboard fiber fraction and second number being the bi-component binderfiber fraction (80/20 is about 80% paper fiber and about 20%bi-component). The cardboard/paper fiber component is made of about50/50 fiberized cardboard/paper up to about 75/25 fiberizedcardboard/paper mix.

The batt material can have a density can be about 25 to about 40 gramsper cubic meter (kg/m3), a thickness of about 12.5 to about 75 mm, andhave fibers (cardboard and binder) with a denier range of about 1 den toabout 3 den. The density of the pad 46 is related to the amount ofcompression of the batt 22 and the percentage of bonding fibers.

Preferably, the material can be formed of about 10% bi-component fiberand about 90% recycled cardboard fiber. The bi-component fiber can bechopped and have a length of less than about 24 mm, less than about 16mm, or a length between about 0.5 mm to about 16 mm, and can be mixturesof two or more lengths, preferably between about 1 mm to about 16 mm.The mixtures of two or more lengths can have ratios of from about 10% toabout 90% of one fiber length to another fiber length and can have anaverage length of less than about 16 mm.

It was found that for a batt sample of about 1300 GSM, about 90%cardboard with the binder being about 10% (with about 50% 1 mm lengthbi-component fiber and about 50% 6 mm length bi-component fiber), over93% of the material is repulpable and therefore recyclable. It should benoted that greater than 85% repulpability is a “passing grade” forrecyclability. The bi-component fibers can be between about 0.5 mm andabout 16 mm polyethylene and polypropylene (“PE/PP”) bi-component; andcan be formed of about a 65/35 percent PE/PP mixture. Optionally, thePE/PP ratio can be between about 65/35 and about 50/50. These fibers canbe, by way of non-limiting example, ES FIBER VISIONS®Polyethylene/polypropylene fiber, including EAC, EPS, ESC, ESE, EDC,Herculon T426 and Herculon T457 versions of fibers.

It was found that a sample of insulation material according to thepresent teachings, when tested for repulpability is repulpable andtherefore recyclable. The insulation material can be repulpable inaccordance with the requirements of the Aug. 16, 2013, revision of the“Voluntary Standard For Repulping and Recycling Corrugated FiberboardTreated to Improve Its Performance in the Presence of Water and WaterVapor” provided by the Fibre Box Association of Elk Grove Village, Ill.which is hereby incorporated in its entirety. In the present aspect, theinsulation material can be recyclable in accordance with therequirements of the Aug. 16, 2013, revision of the “Voluntary StandardFor Repulping and Recycling Corrugated Fiberboard Treated to Improve ItsPerformance in the Presence of Water and Water Vapor” provided by theFibre Box Association of Elk Grove Village, Ill. Containers that includethe insulation material can be single-stream recyclable wherein allmaterials comprised by the container can be recycled by a singleprocessing train without requiring separation of any materials orcomponents of the container. The repulpability test results were asfollows:

Is sample representative of the Y Y material as a whole? (Y/N) STARTINGSAMPLE Moisture Content  7.3%  7.3% Temperature Range 128° F. 128° F.Amount of Fiber in Charge 25 g 28 g Temp & pH Maintained? (Y/N) Y Y HotSlurry Charged to Flat Screen, Y Y as Instructed? (Y/N) FINISHED SAMPLE:Oven dry mass Amount of Fiber Rejects 1.246 g 1.261 g Amount of FiberAccepts 17.84 g 17.27 g Yield of Sample (% Accepts) 93.5% 93.2% Observeand note deposition on vessel walls, screens, moving parts,etc.Deposition Observed? If yes, detail N N (Y/N) below.

It was found that for a batt sample of about 1300 GSM, about 90%cardboard with the binder being about 10% 1 mm bi-component fiber, overabout 98% of the material is repulpable and therefore recyclable. Theinsulations and shipping containers of the present teachings are morethan 85% repulpable with 85% repulpability being a “passing grade” forrecyclability. The repulpability test results were as follows:

Is sample representative of the Y Y material as a whole? (Y/N) STARTINGSAMPLE Moisture Content  7.3%  7.3% Temperature Range 128° F. 128° F.Amount of Fiber in Charge 25 g 25 g Temp & pH Maintained? (Y/N) Y Y HotSlurry Charged to Flat Screen, Y Y as Instructed? (Y/N) FINISHED SAMPLE:Oven dry mass Amount of Fiber Rejects 0.391 g 0.296 g Amount of FiberAccepts 17.83 g 19.28 g Yield of Sample (% Accepts) 97.9% 98.5% Observeand note deposition on vessel walls, screens, moving parts, etc.Deposition observed? (Y/N) N N If yes, detail below

Thermoplastic binder fibers are provided having a weight of less thanabout 0.2 pounds per square foot and, more particularly, preferablyabout 0.1875 pounds per square foot. The remaining reinforcement fiberis greater than about 0.8 pounds per square foot, and preferably about1.0625 pounds per square foot. The binder fibers are preferably amixture of fibers and paper components passed through a hammer mill.

The materials according to the present teaching can have a compressionresistance of between about 0.3 psi and about 1.4 psi for compressionthickness between about 25% and about 50%. For example, a ⅛″ insulationpad has a compression resistance at about 25% thickness of about 0.451psi. The same ⅛″ pad has a compression resistance at about 30% of about0.564 psi. The same ⅛″ pad has a compression resistance at about 50% ofabout 1.81 psi. A ¼″ pad has a compression resistance at about 25% ofabout 0.425 psi. The same ¼″ pad has a compression resistance at about30% of about 0.547 psi. The same ¼″ pad has a compression resistance atabout 50% of about 1.566 psi. A ½″ pad has a compression resistance atabout 25% of about 0.356 psi. The same ½″ pad has a compressionresistance at about 30% of about 0.458 psi. The same ½″ pad has acompression resistance at about 50% of about 1.36 psi. The same ½″insulation pad can have a tear resistance of between about 8.4 and about8.8 lbs.

When an insulated pad of the present disclosure is tested according toASTM Specification C165-07 about 50% relative humidity, the material hasa modulus of elasticity of about 2.64 psi. With a load of about 0.020psi, it sees about a 5% strain. With a load of about 0.29 psi it seesabout a 10% strain, and with a load of about 0.4 psi it sees about a 15%strain. The density of the material can be less than about 5 pounds percubic foot and preferably about 3.5 pounds per cubic foot. The thermalconductivity of the material can be about 0.254 (BTU in/h ft″2 Temp F),the thermal resistance can be about 1.577 (Temp F Ft″2 H/BTU), and thethermal resistivity can be about 3.943 (Temp F Ft″2 h/BTU in). Whentested according to ASTM Specification C165-07, the tested pad also hasan R value of about 1.577.

The insulative pad 46 is formed by heating the paper fiber batt 22 inthe oven to a temperature greater than about 350° F. and, morepreferably, to a temperature of about 362° F. Such heating causes thebinder fibers to melt and couple to the non-binder fibers, thus causingfibers to adhere to each other and solidify during cooling. Uponcooling, the binder fibers solidify and function to couple thenon-binder reinforcement fibers together as well as function asreinforcement themselves.

The insulative paper fiber batt 22 is heated to form the insulative pad46 so it has a density of less than about 10 pounds per cubic foot. Theinsulative pad 46 preferably has a density of less than about 10 poundsper cubic foot and, more preferably, about 8.3 pounds per cubic footwith a thickness of about ¼ inch.

FIG. 12 represents a system 140 to form an insulation liner 142 for afolded box according to another teaching of the present teachings.Generally, the system 140 utilizes a plurality of linked conveyors 144to move an insulated pad 46 as described above through a series ofprocesses to form the insulation liner 142. The system 140 uses acutting apparatus 150 to separate the insulated pad 46 from a continuousbatt 22. A series of rollers 152 are then used to position an upperpaper layer 154 and a lower paper layer 156 about the insulated pad 46.A second cutting apparatus 185 can be used to separate the upper paperlayer 154 and a lower paper layer 156 from the continuous paper layersupply. Additionally or alternatively, a sealing and cutting apparatus186 can be used to cut and seal the edges of the upper and lower paperlayers about the insulated pad 46. A heat tunnel can be positioned abouta conveyor to couple the paper layers 154, 156 about the insulated pad46 to form the insulation liner 142.

FIGS. 13 a-13 b represents the cutting of and formation of an insulativepad 46 from the continuous batt 22. As shown, the batt 22 and pad 46 aretransported along the plurality of linked conveyors 144. The cuttingapparatus 150 can be a circular blade. Additionally, the cuttingapparatus 150 can be a belt blade.

Optionally, the pad 46 can be sliced cross-wise to form two batts havinga partial thickness pad that may be of equal thickness (i.e., thetextile insulative pad is split in half), or that may be of unequalthickness. The present invention is capable of forming a partialthickness batt of about 1/16 of an inch or greater. The startinginsulative pad may be split longitudinally to provide two, three, ormore partial thickness batts.

In the present invention, it has been found that the insulative pad 46may be controllably and accurately split if the feed rollers arepositioned within a predetermined distance from the splitting knife. Thedistance is important because of the compressible and pliable nature ofthe insulative pad. In the preferred embodiment, the predetermineddistance is from about zero to about two millimeters.

The thermoplastic binder fibers and reinforcement fibers are laidrandomly yet consistently in x-y-z axes. The reinforcement fibers aregenerally bound together by heating the binder fibers above their glasstransition temperature. Typically, less than about 20% by weight binderfiber is used, and preferably about 10% binder fiber is used to form theinsulative pad.

Thermoplastic binder fibers are provided having a weight of less thanabout 0.2 pounds per square foot and, more particularly, preferablyabout 0.1875 pounds per square foot. The remaining reinforcement fiberis greater than about 0.8 pounds per square foot, and preferably about1.0625 pounds per square foot. The binder fibers are preferably amixture of thermoplastic polymers which comprise polyethylene/polyesteror polypropylene/polyester or combinations thereof.

FIGS. 14 a-14 c represents the application of an upper paper layeraccording to the present teachings. The series of rollers 152 are thenused to position the upper paper layer 154 and the bottom paper layer156 about the insulated pad 46. As shown, the roller 152 can bepositioned at an angle which is non-perpendicular to the direction ofthe moving conveyor. Preferably, this angle can be about 45 degrees tothe direction of flow of the conveyor.

FIGS. 15 a-15 b represents the application of the bottom paper layer156. Once the upper paper layer 154 is positioned above the pad 46, therollers 152 can position the lower paper layer 156 below the pad 46 atthe intersection of two conveyors 144. The second cutting apparatus 185is used to separate the upper paper layer 154 and the lower paper layer156 from the continuous paper layer supply.

FIGS. 16 a and 16 b represent side sealing of the paper layers 154, 156about the insulative member. In this regard a series of cutting andsealing rollers 186 both cut and seal the sides of the paper layers 154,156 using recycling-compatible or water soluble adhesive. The cuttingand sealing rollers 186 are biased onto the paper layers 154, 156 usinga load such as a spring.

FIG. 17 represents the heat tunnel 110 optionally used to form the boxinsulative member or insulative batt according to the present teachingsshould a heat sensitive recycling-compatible or water soluble adhesivebe used. Once the construction is sealed on all sides, the subassemblyis passed through the heat tunnel 110 which seals the upper and lowerpaper layers 154 and 156 about the insulative pad 46.

As shown in FIGS. 18 a and 18 b , the insulative batt 22 is coupled to acorrugated box 158. Optionally, the insulating batt 22 can be directlycoupled to the box or to an intermediary paper layer 160 prior to thebox being cut into its form for a folded box 142. When used to form thepad 46, the binder material, in the form of recycling-compatible orwater soluble adhesive or meltable fibers, can be preferably recyclableor biodegradable and can be preferably selected from the groupcontaining polyethylene, polyester, polypropylene, and mixtures thereof.

The insulation batt 22 can be used in containers having a polymerbladder for holding liquids or storing gases, or packaging forphotosensitive or like materials. In the regard, the insulation batt 22can be used to hold the temperature of the materials described above orbelow ambient.

Optionally, the box 158 can be, for example, a flat box with thermalinsulation on the top and bottom surfaces (for example a pizza box). Itis envisioned the containers can be used to regulate the change oftemperature within the box. For example, the container can contain adevice such as a recyclable cold pack which will provide a specificenvironment for contents, e.g. temperature above or below ambient withthermal insulation. In this regard the cold pack can be a recyclablemember which is perforated and holds, for example, dry ice. Thecontainers can be formed by folding or erecting paper blanks.Incorporated into the containers can be removable or non-permanentlysecured closure members. The containers can include the insulation layerthat includes shock-absorbing properties.

The containers, packaging elements, or packages using the insulationaccording to the present teachings can be adapted to protect organisms,articles, or materials presenting particular transport environmentchallenges. In this regard, the insulated box can be used to transportlive plants or animals. The container can include an integral couplingor dispensing feature to allow the filling or dispensing of carriedmaterials into the insulated container.

The paper, insulation construction is specially adapted to protectcontents from mechanical damage. In this regard, the container can havea polygonal cross-section provided with internal protecting layers forcontents. Containers or packages can have a special mechanism such as afoldable member or a funnel for dispensing contents, including formedpouring spouts, or dispensing means incorporated in removable ornon-permanently secured container closures.

According to the present teachings, a method of forming an insulated boxis presented. The method includes, forming paper fibers by passingrecycled cardboard through a hammer mill, and mixing paper fibers with arecyclable compatible binder fibers to form mixtures of between 2% and25% recycling compatible fibers and the balance paper and cardboardfibers. This material is then formed into a paper fiber batt from therecycled paper fibers and having a first width and first length having aweight between 1000 and 1600 gsm. Optionally, a recyclable first paperlayer is coupled to the paper fiber batt on a first side of the batt.The fiber batt can be placed within or coupled to a corrugated box. Thepaper layer can be coupled to the corrugated paper element, or the battcan be directly coupled to a surface layer of the cardboard. Optionally,a recyclable second paper layer can be coupled to the paper fiber batton a second side of the batt.

The batt can be formed by melting the binder fibers described above. Thefirst paper layer can be coupled to the paper fiber batt by heating thepaper layer or disposing one of a recycling-compatible or water solubleadhesive between the first paper layer and the batt. The first andsecond layers of recyclable paper can be disposed about the insulationto form a pocket. The first and second layers can be coupled to opposedsides of fiber paper layer by sewing or adhering with one ofrecycling-compatible or water soluble adhesive the pair of opposedsides. The binder fibers are selected from the group consisting of PVOH,polyethylene, polyester, polypropylene, bi-component and mixturesthereof. The insulative pad is about ¼ to about 1 inch thick.

An insulative mailer can be formed by cutting a first paper sheet, andcoupling a first side of a paper fiber pad having a fibrous web of paperfibers distributed substantially randomly to the first paper sheet. Thefibrous web of paper fibers can be interlocked to the first paper sheet.The insulative pad is coupled to a portion of an interior surface of acorrugated cardboard box. After coupling the fibrous web to the interiorsurface of the box, the process includes stamping an exterior perimeterof the box and folding the corrugated box. The fibers can be interlockedto the paper and cardboard fiber using heat, be it radiant throughrollers or steam, to have a density of less than about 10 pounds percubic foot.

To recycle the insulated containers according to the present teachings,clean, used insulated corrugated containers are collected, in manyinstances as part of a mixed recyclables stream such as single-streamrecycling. To optimize recyclability, containers should be free ofcontaminants such as food, metal foil, wax, etc. The collected insulatedcorrugated containers are sorted, compacted, and baled withnon-insulated corrugated containers for space-efficient storage andhandling, either at the point of end-use (store or business) or at therecycling center. Bales are broken open, and the insulated corrugatedcontainers are put into a repulper. The repulper is a huge tub having anagitatable member which agitates the containers with heated water. Thewater can preferably have a temperature above about 100 degrees F. Theyare agitated to form a slushy pulp (slurry) of fiber and water.

The repulper can have a chain or rope which hangs down into the swirlingtub of material used to remove larger contaminates such as twine andlong pieces of rope, string or tape, plastic and metal bands that willwrap around the chain and can then be pulled out of the repulper. Theremaining pulp slurry goes through different filters where additionalmetal falls to the bottom for removal, screens, cyclones, and even bigtanks where the contaminants float to the top and can be scraped off.The cleaned pulp is then sent to the paper machine.

In the typical paper machine the highly diluted fiber solution is pouredout on to a moving screen which allows water to drain away, forming acontinuous fiber mat. The continuous fiber matt is pressed betweenrollers to remove more water. The wet, continuous fiber web is thenpassed through the dryer where the top and bottom of the web alternatelycontact the heated surfaces of the drying cylinders, removing theremaining moisture from the paper. At the end of the paper machine,paper is rolled up on a large reel spool.

Corrugated board is formed from this material using three or more piecesof paper containerboard. The outer surfaces are linerboard and theinner, fluted paper is called medium. A sheet of paper which will becomethe corrugated medium can be softened with steam, and then fed through amachine called a single facer. The medium passes between two huge metalrolls with teeth which give it wavy ridges or “flutes”. Starch adhesiveis applied to the fluted medium, which is then sandwiched between twoflat sheets of paper (linerboard). The insulated material, as describedabove, can be coupled to the cardboard to form a recycled insulatedconstruction. In this regard, the insulating material can be directlycoupled to the box, or recyclable paper disposed about the insulation.

The combined, 3± layer board with associated insulation is then passedthrough curing sections in a continuous web, and then is scored, cutinto proper size blanks (sheets), and stacked. To manufacture a new box,the corrugated sheets are passed through machines that print, score, diecut, and fold them. The side seam of the box (manufacturer's joint) isfastened by gluing, taping, or stitching.

Example embodiments are provided so that this disclosure will bethorough, and will fully convey the scope to those who are skilled inthe art. Numerous specific details are set forth such as examples ofspecific components, devices, and methods, to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to those skilled in the art that specific details need not beemployed, that example embodiments may be embodied in many differentforms and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known processes,well-known device structures, and well-known technologies are notdescribed in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a,” “an,” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The terms “comprises,” “comprising,” “including,” and“having,” are inclusive and therefore specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof. The method steps, processes, and operations described hereinare not to be construed as necessarily requiring their performance inthe particular order discussed or illustrated, unless specificallyidentified as an order of performance. It is also to be understood thatadditional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,”“connected to,” or “coupled to” another element or layer, it may bedirectly on, engaged, connected or coupled to the other element orlayer, or intervening elements or layers may be present. In contrast,when an element is referred to as being “directly on,” “directly engagedto,” “directly connected to,” or “directly coupled to” another elementor layer, there may be no intervening elements or layers present. Otherwords used to describe the relationship between elements should beinterpreted in a like fashion (e.g., “between” versus “directlybetween,” “adjacent” versus “directly adjacent,” etc.). As used herein,the term “and/or” includes any and all combinations of one or more ofthe associated listed items.

Although the terms first, second, third, etc. may be used herein todescribe various elements, components, regions, layers and/or sections,these elements, components, regions, layers and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, layer or section from another region,layer or section. Terms such as “first,” “second,” and other numericalterms when used herein do not imply a sequence or order unless clearlyindicated by the context. Thus, a first element, component, region,layer or section discussed below could be termed a second element,component, region, layer or section without departing from the teachingsof the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,”“lower,” “above,” “upper,” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. Spatiallyrelative terms may be intended to encompass different orientations ofthe device in use or operation in addition to the orientation depictedin the figures. For example, if the device in the figures is turnedover, elements described as “below” or “beneath” other elements orfeatures would then be oriented “above” the other elements or features.Thus, the example term “below” can encompass both an orientation ofabove and below. The device may be otherwise oriented (rotated 90degrees or at other orientations) and the spatially relative descriptorsused herein interpreted accordingly.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the disclosure. Individual elements or featuresof a particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.The same may also be varied in many ways. Such variations are not to beregarded as a departure from the disclosure, and all such modificationsare intended to be included within the scope of the disclosure.

That which is claimed is:
 1. A modular box assembly comprising: a boxformed of a paper blank, the box comprising multiple side box panels anda bottom box panel and defining an interior and a bottom; an insulationliner positioned within the box interior, the insulation linerconstructed of a length of a batt assembly, the batt assembly comprisingan insulation batt in facing contact with a first paper layer and with asecond paper layer, the insulation liner defining multiple sections,wherein at least one section of the insulation liner contacts a side boxpanel of the multiple side box panels, and wherein another section ofthe multiple sections of the insulation liner contacts the bottom boxpanel; and wherein the insulation batt is formed from a mixture ofcellulose reinforcement fibers interlocked with thermoplastic binderfibers distributed substantially randomly within the cellulosereinforcement fibers, the thermoplastic binder fibers making up about0.5% to 25% by weight of the insulation batt, the insulation batt havinga thickness that is at least about 1/16 of an inch, and whereinsubjecting the insulation batt to a repulpability test produces greaterthan 85% fiber yield, and wherein the cellulose fiber pad has a densitywithin a range from 1000 GSM to 1600 GSM, and wherein the repulpabilitytest follows requirements set by Fibre Box Association of Elk GroveVillage, Ill., and recited in Voluntary Standard For Repulping andRecycling Corrugated Fiberboard Treated to Improve Its Performance inthe Presence of Water and Water Vapor as revised on Aug. 16,
 2013. 2.The modular box assembly of claim 1, wherein the thermoplastic binderfibers are comprised of at least one of polyethylene, polyester,polypropylene, and polyvinyl alcohol (PVOH).
 3. The modular box assemblyof claim 2, wherein the thermoplastic binder fibers are comprised of abi-component fiber comprised of polyethylene (PE) and polypropylene(PP).
 4. The modular box assembly of claim 3, wherein a ratio of PE toPP ranges from 50/50 to about 65/35.
 5. The modular box assembly ofclaim 1, wherein the first paper layer is sealed to the second paperlayer such that the insulation batt is encapsulated between the paperlayers.
 6. The modular box assembly of claim 5, wherein each edge of thefirst paper layer is heat sealed to one edge of the second paper layer.7. The modular box assembly of claim 1, wherein the second paper layeris a portion of the paper blank such that the insulation batt is infacing contact with at least one portion of the box.
 8. The modular boxassembly of claim 1, wherein the insulation batt is adhered to at leastone portion of the box.
 9. A modular box assembly comprising: a boxformed of a paper blank, the box comprising multiple side box panels anda bottom box panel and defining an interior and a bottom; an insulationliner positioned within the box interior, the insulation linerconstructed of a length of a batt assembly, the batt assembly comprisingan insulation batt in facing contact with a first paper layer and with asecond paper layer, the insulation liner defining multiple sections,wherein at least one section of the insulation liner contacts a side boxpanel of the multiple side box panels, and wherein another section ofthe multiple sections of the insulation liner contacts the bottom boxpanel; and wherein the insulation batt is formed of a mixture of paperfibers and thermoplastic binder fibers distributed substantiallyrandomly within the paper fibers, the thermoplastic binder fibers makingup about 0.5% to 25% by weight of the insulation batt, the insulationbatt having a thickness that is greater than or equal to about 1/16 ofan inch, the thermoplastic binder fibers being adhered to the paperfibers, and wherein subjecting the insulation batt to a repulpabilitytest produces greater than 85% fiber yield, and wherein thethermoplastic binder fibers are comprised of a bi-component fiber, andwherein the repulpability test follows requirements set by Fibre BoxAssociation of Elk Grove Village, Ill., and recited in VoluntaryStandard For Repulping and Recycling Corrugated Fiberboard Treated toImprove Its Performance in the Presence of Water and Water Vapor asrevised on Aug. 16,
 2013. 10. The modular box assembly of claim 9,wherein the thermoplastic binder fibers are comprised of at least one ofpolyethylene, polyester, polypropylene, and polyvinyl alcohol (PVOH).11. The modular box assembly of claim 10, wherein the thermoplasticbinder fibers are comprised of a bi-component fiber comprised ofpolyethylene (PE) and polypropylene (PP).
 12. The modular box assemblyof claim 11, wherein a ratio of PE to PP ranges from 50/50 to about65/35.
 13. The modular box assembly of claim 9, wherein the first paperlayer is sealed to the second paper layer such that the insulation battis encapsulated between the paper layers.
 14. The modular box assemblyof claim 13, wherein each edge of the first paper layer is heat sealedto one edge of the second paper layer.
 15. A modular box assemblycomprising: a box formed of a paper blank, the box comprising multipleside box panels and a bottom box panel and defining an interior and abottom; an insulation liner positioned within the box interior, theinsulation liner constructed of a length of a batt assembly, the battassembly comprising an insulation batt in facing contact with a firstpaper layer and with a second paper layer, the insulation liner definingmultiple sections, wherein at least one section of the insulation linercontacts a side box panel of the multiple side box panels, and whereinanother section of the multiple sections of the insulation linercontacts the bottom box panel; and wherein the insulation batt is formedof a mixture of cellulose fiber and between about 0.5% and about 25%thermoplastic binder fiber distributed substantially randomly within thecellulose fiber, said thermoplastic binder fiber being adhered to thecellulose fiber, wherein the thermoplastic binder fiber has a length ofbetween about 0.5 mm to about 16 mm, and wherein subjecting theinsulation liner to a repulpability test produces greater than 85% fiberyield, and wherein the density of the batt is less than 5 pounds percubic foot, and wherein the repulpability test follows requirements setby Fibre Box Association of Elk Grove Village, Ill., and recited inVoluntary Standard For Repulping and Recycling Corrugated FiberboardTreated to Improve Its Performance in the Presence of Water and WaterVapor as revised on Aug. 16,
 2013. 16. The modular box assembly of claim15, wherein the thermoplastic binder fibers are comprised of at leastone of polyethylene, polyester, polypropylene, and polyvinyl alcohol(PVOH).
 17. The modular box assembly of claim 16, wherein thethermoplastic binder fibers are comprised of a bi-component fibercomprised of polyethylene (PE) and polypropylene (PP).
 18. The modularbox assembly of claim 17, wherein a ratio of PE to PP ranges from 50/50to about 65/35.
 19. The modular box assembly of claim 15, wherein thefirst paper layer is sealed to the second paper layer such that theinsulation batt is encapsulated between the paper layers.
 20. Themodular box assembly of claim 19, wherein each edge of the first paperlayer is heat sealed to one edge of the second paper layer.